Method of producing metals.



d'OI-IN J. BOERICKE, OF MERION, PENNSYLVANIA.

METHOD OF PRODUCING METALS.

Specification of Letters Patent.

Patented Aug. 27, 1918.

No Drawing. Application filed July 20, 1914, Serial No. 851,888. Renewed June 29, 1918. Serial No. 242,665.

To all whom it may concern Be it known that I, JOHN J. Bonmoxn, a citizen of the United States, residing at Merion, in the county of Montgomer and.

State of Pennsylvania, haveinvente certain new and useful Improvements in Methods of Producing Metals, of which the following is a Specification.

This invention relates to the reduction of metals particularlv rarer metals, such for example as van-o ium, chromium, manganese, and the like, by what is known as the alumino-thermic process, wherein metallic aluminum, a mixture of aluminum or an alloy ofaluminum, or other material havin anaflinity for oxygen, is used as the ucing agent. The pr1mar object of my invention is the provision 0 an improved method whereby the rarer metals can be produced very economically and the comparative yield of and the quality of the finlshed product greatly increased and im-' proved.

The foregoing, together with such other ob'ects as may hereinafter appear, or are inci ent to my invention, I attain by means of an im roved method which will be fully described? It has long been known that metallic aluminum is a powerful agent in reducing ores, and it has also been known that when the aluminum used is in a very finely pulverized condition, the reaction between the aluminum and the oxids, sulfids or chlorids, as the case may be, if started in a portion of the mixture, will continue throughout the mass; in other words, an exothermic reaction takes lace. Because of the fact that aluminum is an ex ensive reducing agent, its application has duction of metals and alloys of comparativel hi h value. The cost of production has een arge not only because of the fact that it was considered necessa to finely pulverize the aluminum, but a so because the metallic ores or compounds from which the desired metal was to be reduced were likewise pulverized in carrying out the known processes. As previously stated, it is one of the chief objects of my invention to reduce the cost of production not only by making the process less expensive, but also by improving and increasing the yield and the quality of the finished product.

In carrying out my improved method, I haveidiscovered that in place of the finely en limited to the propulverized aluminum heretofore used in the art, aluminum in the form of ingots can be emplo ed. Aluminum 1n ingot form IS only slight y more expensive than the ordinary so ingot aluminum which is the cheapest commercial form in which aluminum is sold. In the practice of my invention, I prefer to employ ingot aluminum of which the ingots or lumps vary in size from in the neighbor-' hoodof one-eighth of an inch in diameter,

to three-quarters of an inch, or an inch in diameter. Ingot aluminum 15 aluminum in y solid, lump form and may include anular ingot aluminum which is also in solid, lump form, but is usually made by dropping the I hot metal into water, thus forming what is ordinarily termed shot, the dimensions of 11' which may vary considerably.

It will be understoodthat the aluminum is mixed with the ore or compounds in a crucible or other "easel 'in any desired roportion, and a reaction started, preferably by igniting a portion of the mixture from which the reaction spreads throughout the "180 mass. Where ingots of aluminum are used, it is not necessa to pulverize the ores or compounds, and I prefer not to do so, as the finished product is somewhat improved in quality. It will of course be understood that y the ores are crushed before reduction, but according to my process it is not essential that they be pulverized.

In order to effect an additional saving in cost, as a preliminary step I prefer to preheat the raw materials entering into the reaction, and such preheating may be done either before or after the mixing of the aluminum with the metallic compound. The

reaction, however, should be instituted before the heated materials cool. I have found that this step results in a substantial increase of yield, and it is particularly useful in reducin the oxids of the rarer metals, as,

for examp e, 'in the manufacture of ferrovanadium; Another advantage incident to this step is that a saving is effected in the amount of aluminum required for the reducing operation. I have also found that my improved method secures superior results from low grade ores, that is, ores which contain only a small percentage of the rare metal to be reduced. In fact I have been able to reduce a superior product from ores hitherto regarded as useless. An additional saving, as well as better results, are obtained by also preheating the crucible or other form exothermic reaction.

of container which is used to carry out the reduction.

My invention also contemplates an additional step tending to increase the quantity and quality of yield, and this step consists 1n subjecting the ores, just revious to their reduction, to the action 0 the atmosphere so is to insure complete oxidization. I prefer to take this step when preheating the ores at which time it can readily done by simply opening the furnace doors to create a draft over the ore andthen in stirring or agitating the ore. A large amount of oxygen is thus absorbed by the ore and I have found by experience that this step has a material effect, on the resultant product.

It will be obvious that the method can be used not only to reduce metals, but also alloys.

1. The herein described process of producing' metals or alloys from metallic compounds which consists. in mixing ingot aluminum withthe compound and in instituting an cxothcrmicfreaction. V I i 2. The herein describcd'process of producing metals or alloys from metallic compounds which consists in preheating the 7 compound, in mixingiingot aluminum with 'minum with the compound, in, pre eating the 'compoi'lnd,- and then in institutingan 3. The hereindescribcd of produc i 'ig'inetals or alloys from inetalhc com-- pounds which consists in mixing in ct aluthermic'reaction.

- 4. 'l he-herein described of producmg metals '01" alloys. from metallic compounds which'consists in mixing ingot aluminum with the com the aluminum before a institutin 5. Theli ing metals or alloys from metallic compounds which are not finely divided, which consists in mixing with the compound ingot aluminum, and then in instituting an exothermic reaction.

6. The herein described step of treating metallic compounds preparatory to reduction by the ahuuino-thermie process which consists in subjecting the compound by agitation to the actiouof the atmosphere to secure oxidization.

7. The herein described step of treating metallic compounds preparatory to reduction by the alumino-thermic process which consists in preheating the compound and subjecting it by agitation to the action of the atmosphere to secure oxidizatio 8. The herein described step of treating metallic compounds preparatory to reduction by the alumino-thermic 'ptocesswhich consists in mixing a reducin agent in ingot form with the compound to reduced, and then. in instituting an'egather-mic reaction.

The herein described ste "in producing metals or alloys from inetallid'coinpounds und, in preheating mixture, and then in exothermic reaction.

'by the aluminothermic process yi'hich cons sts in carrying out the reactioiian'ithmlliminum 1n lump form.

ercin described process of produc-.

In testimony whereof I lnveiereaiite siincd my name in the su scribed witnesses.

- Y JOHN Bonin Vitnesses:

'L.A.Mrnizs, f.

An'rimn SYNNESTVEM.'

presence o'f thdt'ivo 

